M15LAP6 Timer Control

EI.ECTRO-FI.UID
LEARNING

POWER SYSTEMS ACTIVITY

PACKET

~--it
IAMATROLr
BB861·XA06XEN
 LEARNING ACTIVITY PACKET 6

TIMER CONTROL

INTRODUCTION
In this LAP you will first learn about the function and operation of time-delay relays
and their applications. The time-delay relay is a type of control relay that switches its
contacts to a new state after a predetermined time has elapsed. It is popularly used in fluid
power applications to cause a dwell between steps as with a plywood press or a plastic
injection molding machine.
You will also learn about the operation of photo-electric sensors. Photo-electronic
sensing is useful in applications to sense the presence of objects without making physical
contact.

ITEMS NEEDED
Amatrol Supplied
For Pneumatics Curriculum
1 85-EP Electro-Pneumatic Relay Control System or
85-EF Electro-Fluid Power Relay Control System
1 85-BP Basic Pneumatics System
1 16019 Electric Power Supply
For Hydraulics Curriculum
1 85-EH Electro-Hydraulic Relay Control System or
85-EF Electro-Fluid Power Relay Control System
1 85-BH Basic Hydraulic System, 850 Bench (either 850-Cl or 850-Hl)
1 85-HPS power supply or an 850-Cl Bench (either 850-Cl or 850-HI)
1 16019 Electric Power Supply

School Supplied
1 79-921 Air Compressor or equivalent
1 Sheet of White Cardboard
1 Sheet of Black Cardboard

SECOND EDITION, LAP 6, REV. A

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, 1ST, lTC, VEST, and Technovate are trademarks or registered trademarks of Amatrol,
Inc. All other brand and product names are trademarks or registered trademarks of their respective companies.
Copyright © 201 0 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, electronic,
optical, mechanical, or magnetic, including but not limited to photographing, photocopying, recording or any information storage and
retrieval system, without written permission of the copyright owner.
Amatrol, Inc., 2400 Centennial Blvd., Jeffersonville, Indiana 47130 USA, Phone 812-288-8285, FAX 812-283-1584

BB861-XA06XEN TIMER CONTROL 2

Copyright © 201 0 Amatrol, Inc.
TABLE OF CONTENTS

SEGMENT 1 TIME·DELAY RELAYS 4

OBJECTIVE 1 Describe the function of a time-delay relay and give an application
OBJECTIVE 2 List two types of time delay relays and give an application of each
OBJECTIVE 3 Describe the operation of an on-delay timer relay and give its schematic symbol
SKILL 1 Connect and operate a control circuit with a timer relay
SKILL 2 Design a time-driven traffic light circuit
OBJECTIVE 4 Describe the operation of an off-delay timer relay and give its schematic symbol

SEGMENT 2 TIMER APPLICATIONS 18

OBJECTIVE 5 Describe the operation of an unloaded motor start circuit
SKILL 3 Connect and operate a control circuit to perform an unloaded start of a motor
OBJECTIVE 6 Describe the operation of a cylinder dwell circuit
SKILL 4 Connect and operate a cylinder dwell control circuit
OBJECTIVE 7 Describe the operation of time-driven sequencing
SKILL 5 Connect and operate a control circuit to perform time-driven sequencing
SKILL 6 Design a control circuit to perform a cylinder dwell

SEGMENT 3 PHOTOELECTRIC SENSOR OPERATION 40

OBJECTIVE 8 Describe the function of a photoelectric sensor and give an application
OBJECTIVE 9 List two types of photoelectric sensors and give an application of each
OBJECTIVE 10 Describe the operation of a photoelectric sensor and give its schematic symbol
SKILL 7 Connect and operate a photoelectric sensor
Activity 1 Sensing range of a photoelectric sensor

SEGMENT 4 PHOTOELECTRIC SENSOR APPLICATIONS 57

OBJECTIVE 11 Describe the operation of three types of photoelectric detection methods
OBJECTIVE 12 Define two types of light reflection and explain their application
OBJECTIVE 13 Describe five characteristics that affect photoelectric sensor performance
SKILL 8 Design a cylinder reciprocation circuit that uses a photoelectric sensor

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 1

Some industrial machines use time control to sequence the events of their
operation. A typical device used to do this is a time-delay relay. The time-delay
relay is a type of control relay that switches its contacts to a new state after a
predetermined time has elapsed. It is popularly used in fluid power applications
to sequence cylinder operation, cause a dwell between steps in a sequence, and to
start electric motors in the unloaded condition. Figure 1 shows a typical industrial
timer relay.

Figure 5. Industrial Timer

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 2

• Thi•
• fII
There are two major logic functions a timer relay can perform:
iii
• ON-Delay
• OFF-Delay
ON-Delay Timer Relay
An On-Delay timer gets its name from the fact that once the timer has received
its signal to activate, or turn on, a predetermined time interval must pass before its
contacts energize.
The timer can be wired into the circuit to either turn on or turn off a load once
the timer has timed out.
A hydraulic plywood manufacturing press is an example of the use of an
On- Delay timer. The plywood layers are held together for a specific length of time
by the press to allow the glue to set. After the timer has timed out, the press retracts
and the finished plywood is removed.

OFF-Delay Timer Relay

The Off-Delay timer operates just the opposite of an on-delay timer. When
the off-delay timer no longer receives an active signal, or is turned off, the timing
mechanism then begins timing. When a predetermined time passes, the timer oper-
ates its contacts, turning the load on or off.
An example of off-delay logic is a fan that comes on for a period of time after
a computer is turned off in order to cool down the computer.
Figure 2 shows examples of time delay relays with various types of timing
mechanisms.

PLUG·IN TIME-DELAY PROGRAMMABLE SOLID STATE DELAY-ON-MAKE

TIMING RELAYS TIMING RELAYS TIMING RELAYS

MULTI-FUNCTION SOLID-STATE ANALOG MINIATURE SOLID-STATE MOTOR-DRIVEN

SOLID-STATE TIMING RELAYS DELAY-ON-MAKE TIMING RELAYS
TIMING RELAY TIMING RELAYS

Figure 2. Time Delay Relays with Various Timing Mechanisms

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 3

All timer relays consist of three basic components:

• Coil - When electrical current is applied to the coil, it causes the contacts to
change states.
• Contacts - A time-delay relay has one or more sets ofN.O. or N.C. contacts.
The contacts open or close after the timing mechanism times out.
• Timing Mechanism - The timing mechanism determines the time delay.
Common timing mechanisms include pneumatic timers, solid-state timers,
and motor driven timers.
Solid-state, time-delay relays use resistor-capacitor networks to perform the
time delay function. The delay time is adjusted by changing the capacitance or
resistance of the internal circuitry by rotating a knob.
The time-delay relay used on the 850 series trainer, shown in figure 3, is an
on-delay type relay that uses solid state electronic components.

TIME DELAY
ADJUSTMENT
KNOB

TIMER
MODULE

Figure 3. Solid-State Timer Relay

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 The cost of a solid-state timer relay is very low compared to other types of
timer relays and they can easily be replaced. When the units go bad, it is cheaper to
replace the device. They are usually enclosed in epoxy resin for protection, making
repair impossible.
Figure 4 shows the ladder diagram symbols for an on-delay relay. Timer relays
sometimes also include a set of instantaneous contacts that energize when the coil
energizes and deenergize when the coil deenergizes. These contacts work just like
a standard relay.

ON-DELAY RELAY

-e- COIL N.O. CONTACT

HR
N.C. CONTACT
HR

INSTANTANEOUS INSTANTANEOUS
N.O. CONTACT N.C. CONTACT

~r-
HR
--N--
HR

Figure 4. Ladder Diagram Symbols for an On-Delay Timer Relay

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Copyright © 201 0 Amatrol, Inc.
 The operation of an on-delay timer relay is shown in figures 5 and 6. When coil
1TR is deenergized, as shown in step 1 of figure 5, the timer relay contacts are in
their normal states and the internal clock is reset to zero.
In step 2, the coil 1TR is energized. This causes the timer's internal clock to
run but the contacts remain in their normal states because the timer has not yet
timed out.
If the pushbutton is released before the timer times out, the coil will deenergize
and the timer will reset to zero.

STEP 1: TIMER COIL OFF, TIMER RESET

TIMER COIL
L1 1PB L2 1TR
1 ---1...-
3
o------.:::~---{

1 1TR A 4
2

1 1TR B 5 TIME
3~~~r-----~------~%1~~~ DELAY
SETTING

STEP 2: COIL HR ENERGIZED, TIMER STARTS

L2
1TR
1PB 3

1 1TRA 4
2
TIME
1 1TR B 5 DELAY
3~~~c~----~------~: SETTING

Figure 5. On-Delay Timer Operator, Steps 1 and 2

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Copyright © 2010 Amatrol, Inc.
 In step 3 of figure 6, the timer's internal clock has reached the preset time and
the relay contacts energize.
The relay contacts will remain energized as long as coil 1TR is energized.
When the coil is deenergized, the contacts will immediately return to their normal
states, and the clock resets to zero. This is shown in step 4.

STEP 3: TIMER REACHES PRESET VALUE

CONTACTS ENERGIZE.
L2
1TR
1PB 3 2

1 1TR A 4
2

1TR B TIME
1 5 DELAY
3
~1Iii!dil'" SETTING

STEP 4: COIL HR DE-ENERGIZED, TIMER RESETS

AND CONTACTS GO TO NORMAL STATES
L1 1PB 1TR L2
1----1- 3

1 1TR A 4
2
TIME
1 HR B 5 DELAY
3~~~~----~------~ SETTING

Figure 6. On-Delay Timer Operation, Steps 3 and 4

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Copyright © 2010 Amatrol, Inc.
 SKILL 1

Procedure Overview
In this procedure, you will use a time-delay relay to control a logic circuit.
You will use the normally closed contacts of the time-delay relay to turn off an
indicator lamp after a given time that you will set has elapsed.

o 1. Set up the Amatrol 850 Electro-Fluid Power Systems Control trainer.

o 2. Perform the sub steps to supply power to the trainer.
A. Place the 24 VDC power supply's power switch in the Off position.
B. Place the Electrical Control Module's power switch in the Off position.
C. Connect the #16019 24 VDC power supply to the Electrical Control
Module by plugging the power supply plug-in connector cable #16179
into the jack on the front of the trainer.
D. Turn on the main switch on the 24 VDC power supply.
o 3. Connect the circuit shown in figure 7.

ELECTRICAL CONTROL MODULE e,;~ijI

1i~C.UoP.

L1 1PB L2
1 --L- HR
3 2

HRA
5
, /2
2
/
R
,

Figure 7. Ladder Diagram

o 4. Set the control knob to 5 seconds.

Each mark on the timer is equal to approximately 5 seconds.
o 5. Turn on the control power switch.
o 6. Observe the red indicator lamp.

Red Lamp Status (On/Off)

The lamp should be on at this time.
The red indicator lamp will come on when the power supply is connected,
because the power source, L 1, is wired to the normally closed contacts of the
time-delay relay.

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Copyright © 2010 Amatrol, Inc.
 o 7. Perform the following substeps to operate the control circuit.
A. Press and hold IPB and observe the red lamp.

Red Lamp Status (On/Off)

You should observe that the lamp goes off 5 seconds after the coil is
energized.
B. Release IPB and observe the red lamp.

Red Lamp Status (On/Off)

You should observe the red lamp come on. This indicates that the timer's
contacts have reset to their normal states.
o 8. Set the timer control knob to zero.
o 9. Perform the following substeps to operate the circuit.
A. Press and hold IPB and observe the red lamp.

Red Lamp Status (On/Off)

The red indicator lamp will immediately go off because there is a time
delay of zero. Therefore, the time-delay relay functions as a standard relay
and the contacts shift without any delay when the coil is energized.
B. Release IPB and observe the red lamp.

Red Lamp Status (On/Off)

The indicator lamp will come on because the coil is deenergized and the
contacts return to their normally closed position. This allows current to
flow to the lamp.
010. Repeat step 7 using various settings on the timer control knob to test the
operation of a time-delay relay.
o 11. Perform the substeps to shut down the trainer.
A. Turn off the control power switch.
B. Turn off the 24 VDC power supply.
C. Disconnect and store the electrical wires.

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Copyright © 2010 Amatrol, Inc.
 -;

SKILL 2

Procedure Overview
In this procedure, you will design, connect and operate a time-delay relay
control circuit that will simulate a timed traffic signal.

o 1. Solve the following design problem.

Scenario: Design a control circuit that will simulate a traffic signal with a
pedestrian crosswalk. The circuit should be designed so that a pushbutton
switch can be pressed momentarily to cause the traffic light to immediately
turn red and stay red for 20 seconds. This will allow the pedestrians time to
safely cross the intersection. After 20 seconds, the light should change back
to green.

Figure 8. Traffic Signal With a Pedestrian Crosswalk

Draw your circuit on a separate piece of paper.

o 2. Set up the Amatrol 850 Electro-Fluid Power Systems Control trainer.

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Copyright © 2010 Amatrol, Inc.
 D 3. Perform the substeps to supply power to the trainer.
A. Place the 24 VDC power supply's power switch in the Off position.
B. Place the Electrical Control Module's power switch in the Off position.
C. Connect the #16019 24 VDC power supply to the Electrical Control
Module by plugging the power supply plug-in connector cable #16179
into the jack on the front of the trainer.
D. Turn on the main switch on the 24 VDC power supply.
D 4. Connect the circuit that you designed in step 1.
D 5. Set the control knob to the 20 second time delay.
D 6. Turn on the control power and observe the indicator lamps.

Red Lamp Status ___________________________ (OlliOm

Green Lamp Status (On/Om

The green lamp should be on and the red lamp should be off indicating that
the traffic can flow through the intersection. A pedestrian cannot cross safely
at this time.
D 7. Operate the circuit you designed and connected.
A. Momentarily press 1PB.
Red Lamp Status (On/Om

Green Lamp Status (On/Om

When the pushbutton is pressed, the green lamp should go off and the red
lamp should come on. This will last for 20 seconds. The lamps should
then return to their previous status.
D 8. Demonstrate the circuit to your instructor.
This is part of your skills assessment.
D 9. Perform the substeps to shut down the trainer.
A.. Turn off the control power switch.
B. Turn off the 24 VDC power supply.
C. Disconnect and store the electrical wires.
D 10. Place a copy of your circuit design in your portfolio.

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 4

The off-delay timer relay operates in a manner that is opposite to the on-delay
timer just described. In this mode, when the relay coil is energized, the N.O. and
N.C. contacts immediately change states and stay energized. After the coil has
been deenergized, the timer's mechanism begins timing. The contacts continue to
stay energized during this period until a predetermined time has elapsed. Figure 9
shows the ladder diagram symbols for an off-delay timer relay.

OFF-DELAY RELAY

-e-COIL N.O. CONTACT

1TR
N.C. CONTACT
1TR

INSTANTANEOUS INSTANTANEOUS
N.O. CONTACT N.O. CONTACT
1TR 1TR

-N--
Figure 9. Ladder Diagram Symbols for an Off-Delay Timer Relay

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Copyright © 201 0 Amatrol, Inc.
 Figures 10 and 11 show the off-delay timer operation in four steps. In step 1,
the timer relay contacts are deenergized and the coil 1TR is off. When the coil is
energized, the contacts 1TRA and 1TRB immediately switch to their energized
states, as shown in step 2. These contacts will remain energized as long as the coil
is energized. The internal clock of the off-delay timer relay does not run while the
coil is energized.

STEP 1: COIL HR OFF, TIMER CONTACTS

ARE IN THE NORMAL STATE
L1 1PB L2
1 ----1- 1TR
3
o------"----{
1 1TR A 4
2

1 1TR B 5
TIME
3~~~r_----~------~ DELAY
SETTING

STEP 2: COIL HR ENERGIZED, CONTACTS ENERGIZE,

TIMER RESETS
L2
1TR
1PB 3

1 1TR A 4
2~~~r-----~------_{
1 1TR B 5 DELAY
3~<Y~cr_--~---_{ SETTING

Figure 10. Off-Delay Timer Operation, Steps 1 and 2

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Copyright © 2010 Amatrol, Inc.
 When coil 1TR is deenergized by releasing lPB, the internal clock starts
running, as shown in step 3 of figure 11. However, the contacts remain energized.
When the internal clock reaches the preset time, the timer contacts then return to
their normal states, as shown in step 4.

STEP 3: COIL HR DEENERGIZED , CONTACTS STAY

ENERGIZED, TIMER STARTS RUNNING
L1 1PB L2
1 ---1...- 3 1TR 2

1 1TR A 4
2~~~r-------------;
1 1TR B 5
3~~~c~----~------;

STEP 4: TIMER TIMES OUT, CONTACTS DEENERGIZE

L1 1PB L2
1 ---1...- 1TR
3

11TRA 4
2
TIME
11TRB DELAY
5
3 ~~~~ SETTING

Figure 11. Off-Delay Timer Operation, Steps 3 and 4

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 5

Many industrial hydraulic systems use large electric motors to power their
pumps. Starting up a large electrical motor requires more electricity when it is
running at full load. This can increase a company's power bill because many
companies are charged by the peak power use, not the average.
To avoid higher power draws, large motors should be started in the unloaded
condition. One common method of unloading a motor during startup is to use a
control circuit with a timer relay.

Figure 12. An Industrial Hydraulic System

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 SEGMENT 1

1. A relay is a type of control relay that switches

its contacts to a new state after a predetermined time has elapsed.

2. The three basic components of a time-delay relay are the coil, the
contacts, and the _

3. time-delay relays use a resistor-capacitor network

as a timing circuit.

4. The two basic operating modes of a time-delay relay are

_________ and _

5. When the coil of the relay is energized, an timer relay causes

its contacts to change states after the elapsed preset time.

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 Figure 13 shows an example of a control circuit that provides unloaded starting
of an electric motor which drives a hydraulic pump. The pump is unloaded by
unloading the relief valve using valve 1.

PUMP TO SYSTEM FROM SYSTEM

START
L1 L2 2
STOP
2PB ~B 1CR
3 4

1CRA VALVE 1

1CRB HR
5
I
3
L_.J RELIEF
M1 VALVE
5
4

2CR
HRA 6
5
2CRA SOL-A
M1
7
6
MOTOR STARTER
3-PHASE POWER

Figure 13. Unloaded Start Circuit

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 To begin operation, the operator presses the start button, IPB, on the control
panel. This starts the motor and causes the timer relay to begin timing. Because
valve 1 unloads the relief valve, the pump flow returns to the tank at minimum
load.

PUMP
START TO SYSTEM FROM SYSTEM
2

1CRA

1CRB 1TR

•t
5
3

4
5
t
1TRA
6 t
5

2CRA
7
t
6
MOTOR STARTER
3-PHASE POWER

Figure 14. Unloaded Start Circuit after 1PB is Pressed

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Copyright © 2010 Amatrol, Inc.
 When the timer relay times out, contacts 1TRA energize, causing Sol A to in
turn energize. This causes the relief valve to close, allowing the pump to load.

PUMP TO SYSTEM FROM SYSTEM

L1 START L2
STOP
2PB
-1..!.E,B 1CR
3 4
SOL·A

1CRA

1CRB HR
5
3

M1
5
4

2CR
HRA 6
5
2CRA SOL-A
7
6
MOTOR STARTER
3-PHASE POWER

Figure 15. Unloaded Start Circuit After 1PB is Pushed and Timer Has Timed Out

SKILL 3

Procedure Overview
In this procedure, you will connect and operate a control circuit that uses
a timer relay to simulate the unloaded start of a motor.

o 1. Set up the Amatrol 850 Electro-Fluid Power Systems Control trainer.

o 2. Perform the sub steps to supply power to the trainer.
A. Place the 24 VDC power supply's power switch in the Off position.
B. Place the Electrical Control Module's power switch in the Off position.
C. Connect the #16019 24 VDC power supply to the Electrical Control
Module by plugging the power supply plug-in connector cable #16179
into the jack on the front of the trainer.
D. Turn on the main switch on the 24 VDC power supply.

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 o 3. Connect the hydraulic circuit shown in figure 16. If using the pneumatic
trainer, skip to step 4. In this circuit, the red lamp will represent the prime
mover running in an unloaded condition. When the timer times out, the DCV
will shift and cause the motor on the hydraulic actuator module to turn on.

PUMP
L1 START L2 7
STOP
2PB ~B 1CR MOTOR
3 4

1CRA
B
2
A
1CRB HR
5
3

4 5 SIMULATES
UNLOADED
MOTOR
HRA
6
5
2CRA
7
6

Figure 16. Hydraulic Setup of Unloaded Start Circuit

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Copyright © 2010 Amatrol, Inc.
 D 4. If using the pneumatic trainer, set up the simulated circuit in figure 17.
The pneumatic circuit uses the red lamp to represent the motor running in the
unloaded condition. The motor is running in the loaded condition when both
lamps are on.

L1 L2
STOP 2PB
1PB
......L... 1CR

1CRA HR

'CR~
'0.,
/
MOTOR RUNNING
LOADED

'0.,
/
MOTOR RUNNING

Figure 17. Pneumatic Setup of Unloaded Start Circuit

D 5. If using the hydraulic setup, perform the following startup procedures on the
hydraulic power unit. If using the pneumatic setup, skip to step 6.
A. Check the oil level. Fill if necessary.
B. Press the stop push button on the motor starter to make sure the starter is
in the off position.
C. Plug in the power cord to the wall outlet.
D. Reduce the relief valve to its minimum pressure setting.
E. Press the start button on the hydraulic power unit.
E Adjust the relief valve pressure to 300 psi12070 kPa.
G. Open the shutoff valve.
D 6. Set the control knob on the timer to 5 seconds.
D 7. Turn on the control power switch.

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 o 8. Press the IPB momentarily and observe the circuit.
If using the pneumatic trainer, record the status of the indicator lamps. If
using the hydraulic trainer, record the status of the motor and the red lamp.
Green Lamp Status (On/Off)

Red Lamp Status (On/Off)

Motor Ml (running/not running)

The red lamp should come on. This represents the motor starting up in
the unloaded condition. If using the hydraulic circuit, the motor should be
running in an unloaded condition.
o 9. Observe the status of the circuit after the 5 second delay.
Green Lamp Status (On/Off)

Red Lamp Status (On/Off)

Motor Ml (Running/Not running)

Both lamps should be on. This indicates that the motor is loaded. If using
the hydraulic circuit, the motor Ml should be running and the motor should
speed up as more fluid is routed through it.
010. Momentarily press the stop button.
Green Lamp Status _ (On/Off)

Red Lamp Status (On/Off)

Motor Ml (RunningINot running)

The lamps should deenergize. If using the hydraulic trainer, the motor should
be running unloaded and slower.
011. Operate the circuit a few more times to get familiar with its operation.
012. Perform the sub steps to shut down the electrical and hydraulic power:
A. Turn off the control power switch of the Electrical Control Module.
B. Turn off the 24 VDC power supply.
C. Reduce the power unit pressure to minimum.
D. Turn off the power unit.
E. Close the shutoff valve.
F. Manually activate the solenoid override to remove any pressure left in the
circuit.
Trapped pressure can sometimes make it hard to disconnect hoses.
G. Disconnect and store the hoses.
H. Disconnect and store the electrical wires.

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 OBJECTIVE 6

During a machine's operation sequence, the control circuit may be required to

hold a cylinder in a certain position for some period of time before moving, or have
a time delay between the operation oftwo cylinders' strokes. This process is called
cylinder dwell. It is used in many machines including hydraulic presses and plastic
injection molding machines.
For a plastic injection molding machine, like the one in figure 18, hydraulic
cylinders are sometimes used to open and close the two halves of the mold. A
cylinder dwell is used to hold a cylinder in position before moving.
When the mold halves are pushed together or closed, hot melted plastic is
injected into the mold. Before the mold can be pulled apart, a dwell period must
occur to allow the plastic to cool and harden. This dwell period can be created by
a timer relay.

Figure 18. A Plastic Injection Molding Machine

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 Figure 19 shows a cylinder reciprocation circuit with a dwell period before
the cylinder retracts. This circuit uses a timer relay 1TR to accomplish the dwell.

1 1
L1
START
1PB
1CR
L2 ••
OPEN

1CRA
2

1CRB SOL-A
5 2
3 1 EXTEND I
I
I
I
I I

5 6
HR
4

T P

Figure 19. A Cylinder Reciprocation Circuit With a Dwell Period

When the operator presses IPB, relay lCR causes lCRA to seal in, lCRB
contacts close, and solenoid A is energized to extend the cylinder.
When the cylinder becomes extended, it actuates lLS, causing the timer relay
coil 1TR to start timing, as shown in figure 20.

1 1
L1

4
1CR
2
L2
CLAMP
CYLINDER
••
CLOSED

MOLD

1CRA
2

1CRB SOL-A
5 I I
3 1 A. 2 EXTEND I I
~:$ I I

5 6
HR
4 2 i4'IMINGJ

Figure 20. Cylinder Extended, Timer Timing

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"0

After a period of time, the timer times out and forces contacts 1TRA open.
This de energizes the seal-in circuit and solenoid A, causing the cylinder to retract.
The timer relay is also reset because its coil is deenergized when lCRA opens.

START DWELL

1 1
L1

~0t-2 4
1CR
2
L2

CLAMP
CYLINDER L~::::~~~~---------
MOLD

1CR~
2

1CRB SOL-A
3 1 ~-.------~5------~'VC~2~EXTEND
I
I
I
I

5 6
1TR
2 TIMED
4 OUT

Figure 21. Timer Timed Out, Cylinder Retracted

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 SKILL 4

Procedure Overview
In this skill, you will connect and operate the cylinder dwell control circuit
that was discussed in the previous objective.

o 1. Set up the Amatrol850 Electro-Fluid Power Systems Control trainer.

o 2. Perform the substeps to supply power to the trainer.
A. Place the 24 VDC power supply's power switch in the Off position.
B. Place the Electrical Control Module's power switch in the Off position.
C. Connect the #16019 24 VDC power supply to the Electrical Control
Module by plugging the power supply plug-in connector cable #16179
into the jack on the front of the trainer.
D. Turn on the main switch on the 24 VDC power supply.
o 3. Connect the hydraulic circuit shown in figure 22 or the pneumatic circuit in
figure 23.

Figure 22. Hydraulic Setup of a Cylinder Reciprocation Circuit With a Dwell Period

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Copyright © 2010 Amatrol, Inc.
 p

Figure 23. Pneumatic Setup of a Cylinder Reciprocation Circuit With a Dwell Period

D 4. If using the hydraulic power unit, perform the following startup procedures.
If using the pneumatic trainer, skip to step 5.
A. Check the oil level. Fill if necessary.
B. Press the stop push button on the motor starter to make sure the starter is
in the off position.
C. Plug in the power cord to the wall outlet.
D. Reduce the relief valve to its minimum pressure setting.
E. Close both flow control valves and then open each one turn.
E Press the start button on the hydraulic power unit.
G. Adjust the relief valve pressure to 300 psil2070 kPa.
H. Open the shutoff valve.
D 5. If using the pneumatic trainer, perform the following startup procedures. If
using the hydraulic trainer, skip to the next step.
A. Close both flow control valves and then open each one turn.
B. Connect the compressed air supply to the male quick-connect on the
instrumentation module and open the shutoff valve.
C. Turn on the pneumatic air supply.
D. Turn the regulator adjustment CW until the pressure at the regulator gage
reads 30 psi/207 kPa.
D 6. Cycle the cylinder manually and observe the cylinder. It should extend at an
approximate rate of 2-3 seconds. If the cylinder speed needs adjusting, turn
the flow control valves until the desired speed is reached.
D 7. Set the control knob on the timer to 5 seconds.

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 o 8. Turn on the control power switch.
o 9. Press the 1PB momentarily and observe the circuit. Record what happens.

You should observe that the cylinder extends, dwells for a period of 5 seconds,
and then retracts.
010. Repeat step 10 to become more familiar with this cylinder dwell circuit.
011. Perform the substeps to shut down the electrical and hydraulic or pneumatic
power:
A. Turn off the control power switch of the Electrical Control Module.
B. Turn off the 24 VDC power supply.
C. If using the hydraulic trainer:
1. Reduce the power unit pressure to minimum.
2. Turn off the power unit.
3. Close the shutoff valve.
4. Manually activate the solenoid override to remove any pressure left in
the circuit.
Trapped pressure can sometimes make it hard to disconnect hoses.
D. If using the pneumatic trainer:
1. Reduce the regulator pressure to minimum.
2. Close the shutoff valve.
3. Manually activate the solenoid override to remove any pressure left in
the circuit.
E. Disconnect and store the hoses.
F. Disconnect and store the electrical wires.

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Copyright © 2010 Amatrol, Inc.
 OBJECTIVE 7

.tI
.) This Instead of using limit switches to sequence the operation of a machine, timers
lit are sometimes used. This is called time-driven sequencing. For each distinct opera-
tion that takes place, a separate timer must be used. Each timer is wired into the
control circuit so that its coil is energized when a particular step in the machine's
sequence is started.
For example, if a cylinder is the actuator being sequenced, the time delay is
set for the precise amount of time required for the cylinder to extend or retract.
When the timer times out and the cylinder has also completed its stroke, the timer
energizes its contacts to cause a new step to take place.
A cylinder reciprocation circuit that uses a timer to sequence its operation is
shown in figure 24. When IPB is pressed, coillCR seals in and energizes solenoid
A to extend the cylinder. Also, timer relay coil 1TR is energized at the same time
as solenoid A. When the timer times out, it opens contacts 1TRA. This deenergizes
the seal-in circuit and causes the cylinder to retract.

START
L1 L2
1PB
--L 3
HRA 1CR
4

1CRA

1CRB HR
5
3

SOL-A
2
4 CYLINDER
EXTEND

Figure 24. Time-Driven Reciprocation Circuit

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 If the time delay is adjusted to time out exactly when the cylinder reaches the
end of its stroke, the cylinder will operate in the same manner as if it were using a
limit switch.
Figure 25 shows an example of time-driven sequencing control with two cylin-
ders. When the operator presses IPB, cylinder 1 extends and 1TR starts timing.
When 1TR times out, 1TRA closes, energizing 2CR and 2TR. Cylinder 2 extends
as 2TR starts timing and cylinder 1 retracts. When 2TR times out, 2TRA opens,
deenergizing 2CR. Cylinder 2 retracts.

1PB
START
2PB
STOP
----1...-
3
RUNG 1

1CRA

RUNG 2

1CRB SOL-1
6 2
RUNG 3

RUNG 4

2CRA SOL-2
7
RUNGS

Figure 25. Time-Driven Sequencing of Two Cylinders

One of the problems with using a timer relay is that it often requires a number
oftimer adjustments before you get the desired delay time. Using limit switches to
perform event driven sequencing is usually better.

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Copyright © 201 0 Amatrol, Inc.
 SKILL 5

Procedure Overview
In this skill, you will connect and test the operation of a time-driven
cylinder circuit. This circuit will use a time delay instead of a limit switch to
cause the cylinder to retract.

o 1. Set up the Amatrol 850 Electro-Fluid Power Systems Control trainer.

£..
~~ o 2. Perform the following substeps to supply power to the trainer.
A. Place the 24 VDC power supply's power switch in the Off position.
B. Place the Electrical Control Module's power switch in the Off position.
C. Connect the #16019 24 VDC power supply to the Electrical Control
Module by plugging the power supply plug-in connector cable #16179
into the jack on the front of the trainer.
D. Turn on the main switch on the 24 VDC power supply.

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 o 3. Connect the control circuit shown figure 26.

LADDER DIAGRAM POWER DIAGRAM

HYDRAULIC

1PB
2PB ....l.....
3 4

1CR

1CRB SOL-B

2
1- 6 -0",,-0-2..• CYLINDER
EXTEND
PNEUMATIC

Figure 26. Hydraulic and Pneumatic Setup of a Cycle Reciprocation Circuit

o 4. If using the hydraulic power unit, perform the following startup procedures.
If using the pneumatic trainer, skip to step 5.
A. Check the oil level. Fill if necessary.
B. Press the stop push button on the motor starter to make sure the starter is
in the off position.
C. Plug in the power cord to the wall outlet.
D. Reduce the relief valve to its minimum pressure setting.
E. Close both flow control valves and then open each one turn.
P. Press the start button on the hydraulic unit.
G. Adjust the relief valve pressure to 300 psi / 270.
H. Open the shutoff valve.

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Copyright © 201 0 Amatrol, Inc.
 o 5. If using the pneumatic trainer, perform the following startup procedures.
A. Close both flow control valves and then open each one turn.
B. Connect the compressed air supply to the male quick-connect on the
instrumentation module.
C. Open the shutoff valve.
D. Adjust the regulator pressure to 30 psi/207 kPa.
o 6. Extend the cylinder using the manual override and adjust the flow control so
that it takes approximately 5 seconds for the cylinder to complete its stroke.
o 7. Set the control knob on the timer to 5 seconds.
o 8. Turn on the control power switch.
o 9. Perform the following substeps to test the circuit.
A. Press IPB momentarily and observe the operation of the circuit. Record
below whether the timer coil timed out and retracted the cylinder 1 before,
after, or at the exact moment the cylinder became fully extended.

Timer coil timed out:

When IPB is pressed, cylinder 1 should extend and then retract when the
timer coil times out.
010. Adjust the timer relay knob either up or down to make the timer coil time out
at the exact moment the cylinder becomes extended.
011. Then press IPB and observe the results.
Timer coil timed out _
(before, after, or at the exact moment the cylinder became fully extended)
012. Repeat step 10 until you get the time delay to exactly match the time for the
cylinder to extend. Record the number of times required.
____________________ (Number of Tries)

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 013. Perform the steps to shut down the electrical and hydraulic trainer or
pneumatic trainer.
A. Turn off the control power switch of the Electrical Control Module.
B. Turn off the 24 VDC power supply.
C. If using the hydraulic trainer:
1. Reduce the power unit pressure to minimum.
2. Turn off the power unit.
3. Close the shutoff valve.
4. Manually activate each solenoid override to remove any pressure left in
the circuit.
Trapped pressure can sometimes make it hard to disconnect hoses.
D. If using the pneumatic trainer:
1. Reduce the regulator pressure to minimum.
2. Close the shutoff valve.
3. Manually activate each solenoid override to remove any pressure left in
the circuit.
Trapped pressure can sometimes make it hard to disconnect hoses.
E. Disconnect and store the hoses.
F. Disconnect and store the electrical wires.

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Copyright © 201 0 Amatrol, Inc.
 Procedure Overview
In this procedure, you will design a control circuit to perform a cylinder
dwell using a time-delay relay. This skill can be performed with either the
hydraulics or pneumatics trainer.

o 1. Solve the following design problem.

Scenario: You work as an engineer for a company which has designed a
new plastics injection molding machine, as shown in figure 27. This machine
has three basic components to perform the steps of the injection-molding
process: the injection unit, the clamp unit, and the ejector pins.
Plastics material is supplied to the machine's hopper in a granular or pellet
form. The plastic is heated until it melts. Then it is injected or forced into
a mold cavity. The injection pressure is held for a period of time until the
plastic part is solidified in the mold. The pressure is then released, the mold
opens, and the newly-formed plastic parts are ejected by the ejector pins from
the machine.

A. HYDRAULIC·
CLAMP
CYLINDER

Figure 27. Plastics Injection Molding Machine

Your task is to design a circuit to control the injection molding machine. The
control circuit should perform the following functions.
• Pressing pushbutton IPB starts the cycle.
• The mold closes (cylinder 2 extends).
• When the mold is closed (cylinder 2 extended), a limit switch is actuated.
This causes plastic to be injected into the mold ( motor turns on) and timer
starts timing.

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 • After 10 seconds, the motor stops and the mold is allowed to cool. A second
timer starts timing.
• When the mold is fully opened (cylinder 2 retracts and actuates a second
limit switch) the molded parts are ejected (cylinder 1 extends and retracts).
The ejector cylinder uses timers to sequence its steps. The cycle repeats.
• Pressing 2PB at any time causes the machine to stop at the end of its cycle.

EJECTOR

CLAMP
CYLINDER
••
OPEN PINS
EJECTOR
CYLINDER

CYLINDER #2 CYLINDER #1

2LS
MOLD
OPENED

SOL2A SOL2B
CLOSE DL..->-L...L..J'-'::'L....I.:=-,""1-I....L......J
OPEN

L1 L2

0- 3-POSITION
VALVE

F.C. #1 F.C. #2

MOTOR

Figure 28. Hydraulic Setup of a Continuous Reciprocation Circuit

o 2. Show your circuit to your instructor. This is part of your skills assessment.
o 3. Place a copy of your circuit design in your portfolio.

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 PHOTOELECTRIC SENSOR OPERATION

OBJECTIVE 8 o

A photoelectric sensor is an electronic switch that actuates when it senses

light. This characteristic is called non-touch sensing.
Photoelectric sensors are used instead of limit switches in applications where
there is a need for sensing an object without touching it or where the object is
located some distance from the sensor itself. Like limit switches, photoelectric
sensors have N.O. and N.C. contacts that can be wired into control circuits to
sequence events.

Figure 29. A Typical Photoelectric Sensor

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 SEGMENT 2

1. To avoid higher power draw, large motors should be started in an

________ condition.

2. A plastic injection mold is an example of an operation that uses a

_______ dwell.

3. sequencing uses timer relays in place of limit

switches to sequence the operation of a machine.

4. For each distinct operation that takes place in a time-driven operation,

a must be assigned.

5. Before the mold on a plastic injection molding machine is pulled apart,

a period must occur to allow the plastic to cool
and harden.

6. is the process of holding a cylinder in a

certain position for a period of time before moving.

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Copyright © 2010 Amatrol, Inc.
 The sensing range of a photoelectric sensor is many times that of other sensors.
One application where a long sensing distance is needed is in burglar alarm appli-
cations. In a museum, for example, a photoelectric sensor could be placed close
to an exhibit to sense if someone is too close to the exhibit, as shown in figure 30.
Museum visitors can enjoy the museum and the art is protected.

PHOTOELECTRIC TRANSMITTER AND RECEIVER

SYSTEM TO DETECT ANYONE
CLOSE TO THE PICTURE \

Figure 30. Theft Protection

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 Other applications of the photoelectric sensor include non-touch counting or
sensing the presence of objects, as shown in figure 31.

Figure 31. Additional Applications of the Photoelectric Sensor

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 OBJECTIVE 9

Photoelectric sensors generate their own light signal using an internal light
source. The light source originally used in photoelectric switches was an incan-
descent type like the light bulbs in your home. The primary advantage of this type
is you can actually see the light beam, making it easy to align the source with the
receiver and identify when the bulb is burned out. The primary disadvantage of this
type is that it cannot be used in areas where there is a lot of external light, as found
outside or in areas with bright lights.
Another type of light source used is a solid-state, modulated LED (light emit-
ting diode). This type uses an LED that emits light in the invisible region near the
infrared region. Its advantages include:
• Unaffected by external light sources
• Long life
• Rugged construction.
Unaffected by External Light
LED-type photoelectric sensors are unaffected by external light because they
use a modulating light source where the light is emitted at a certain frequency.
The receiver can then be "tuned" to receive only the frequency of the light source.
This feature allows the LED-type photoelectric switch to be used in outdoor
applications.

MODULATED LIGHT

UN MODULATED LIGHT

EMITTER

Figure 32. Infrared Sensing Application

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 A modulated light source also allows the sensitivity of the receiver to be greatly
amplified to the point where an LED infrared photoelectric switch can actually
burn through a cereal box and detect the presence of its contents!

Figure 33. Cereal Detection

Long Life
Another advantage of an LED emitter is its extremely long life. While the
bulb of an incandescent light source must be frequently replaced, the LED's life is
so long that it will actually outlast the switch itself. Consequently, manufacturers
permanently encase the LED in the photoelectric switch. This helps protect the
switch and reduce cost.

Rugged Construction
A third advantage of an LED emitter is its rugged construction. Since the LED
has no bulb to break, it can be reliably used on applications where there is heavy
vibration.
The advantages listed above make the modulated LED-type photoelectric
switch the overwhelming choice for most applications. The only application it
cannot address is the sensing of color differences because the LED only emits light
of one wavelength (color). This application still requires the use of an incandescent
light source.

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 OBJECTIVE 10 oEse' AN

The component contained in a photoelectric sensor that senses light is a photo-

diode. This diode turns on like a switch when it is exposed to a light source and
passes electrical current in a circuit.

I POWER I
I SUPPLY I
+ -
RESISTOR:: NO CURRENT
FLOWS

L••
I'"
PHOTO DIODE

Figure 34. Current Stopped When Photodiode Sees No Light

In figure 35, a light source is aimed at the diode, causing it to open and allow
current to flow.

RESISTOR

JfJfJf
LIGHT

Figure 35. Flows When Photodiode Sees Light

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 A photoelectric switch actually has three components; a light source (trans-
mitter or emitter), a photoelectric sensor (the receiver which contains the photo-
diode) and one or more electrical switch contacts, as shown in figure 36.

TRANSMITIER
SWITCH
/CONTACTS
RECEIVER
LIGHT
SOURCE ~

PHOTO
POWER DIODE
SUPPLY

+
POWER SUPPLY

Figure 36. Components of a Photoelectric Sensor

When light from the sensor's transmitter strikes the receiver, the photo-diode
conducts, energizing the sensor's contacts. The N.O. contacts close and the N.C.
contacts open, as shown in figure 37. When the transmitter light is removed from
the receiver, the contacts return to their normal states.

LIGHT
SOURCE

POWER
SUPPLY

Figure 37. Operation of a Photoelectric Sensor

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 Figure 38 shows the photoelectric sensor on the 850 Electro-Fluid Power
trainer and its schematic symbol. The sensor's emitter and receiver are contained in
one unit. This is because the photoelectric sensor uses reflective sensing to detect
objects instead of opposed sensing.
The photoelectric switch is constructed with a window in the casing. This
allows light to shine through to the diode itself.
A transistor is connected to the photodiode to boost the signal to a level
that is compatible with machine control circuits. This combination is called a
PHOTOTRANSISTOR.
Figure 38 also shows the two status indicators, beam and output, that provide
a quick check of the operating status of the sensor.

Figure 38. Photo Electric Sensor and Schematic Symbol

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 Photoelectric switches are wired into a control circuit in a manner similar to
limit switches except they require a supply power to operate. As shown in figure
39, the Amatrol photoelectric sensor requires power wired to the white and black
wires. The other terminals connect the N.O. and N.C. relay contacts inside the
sensor to an external control circuit.
This particular switch uses proximity detection with both the emitter and
receiver contained in one enclosure. When power is supplied to the sensor and no
object is in range, the sensor sees dark and the contacts are in their normal states.
When an object passes in range of the sensor, it reflects the light back and makes
the sensor "see light". This causes the contacts to energize and stay energized until
the object is removed. A small red LED light on the side of the sensor indicates
when these contacts are energized.
The Amatrol photoelectric switch is an infrared modulated LED-type.

LADDER DIAGRAM
L1 L2
1
(WHITE WIRE) -~---
SENSOR BEAM2

(BLACK WIRE)
(RED
WIRE)
1 C N.O. 3
(GREEN WIRE)

N.C. 4
(BROWN WIRE)

L1 ACTUAL WIRING DIAGRAM L2

(BLACK WIRE} 2
1 (WHITE WIRE}

Figure 39. Ladder Diagram Compared to Actual Wiring of a Circuit Using a Photo-
electric Switch

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Copyright © 2010 Amatrol, Inc.
 SKILL 7

Procedure Overview
In this skill, you will assemble a circuit to test the operation of the
photoelectric switch. Since this particular switch is a proximity type, you will
test the range of sensing and the effects of objects with a variety of surface
types.

o 1. Set up the Amatrol850 Electro-Fluid Power Systems Control trainer.

o 2. Locate the Photoelectric Sensor shown in figure 40 from the 85-EF Electro-
Fluid Power Module.
Take a moment to look at the photoelectric sensor. You should notice that
both the sensor's emitter and receiver are contained in one unit, as shown in
figure 40. This is because the photoelectric sensor uses reflective sensing to
detect objects instead of opposed sensing.

Figure 40. 16096 Photoelectric Sensor from the 85-EF Electro-Fluid

Power Module

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 In the reflective sensing mode, light from the sensor's transmitter strikes
the object and is diffused (reflected) from the object in all directions. The
sensor's receiver picks up some of this reflected light and energizes its
contacts, as shown in figure 41. When the object is removed from the path of
the transmitted light; the contacts return to their normal states.

TRANSMITTER

-----------.
LlGHTj

OUTPUTS DEENERGIZED
(NO LIGHT SENSED BY
RECEIVER)

..---- -=-0\
- - - - -- -=- -:.
~
1Wt.~

OBJECT

OUTPUTS ENERGIZED
(LIGHT REFLECTED FROM
OBJECT TO RECEIVER)

Figure 41. Operation of a Reflective Photoelectric Sensor

Another thing you should notice about the sensor is that it has two status
indicators, beam and output, shown in figure 40. These indicators provide a
quick check of the operating status of the sensor. Specifically, the beam status
indicator (green LED) turns on whenever the infrared beam is detected by the
receiver, while the output indicator (red LED) follows the status of the output
relay.
Notice the red (+) and black (-) jacks on the back of the photoelectric sensor.
These jacks supply the power to the photoelectric sensor. Rung 1 of the
schematic of figure 42 shows how the red and black jacks are connected in
the circuit.
Rungs 2 and 3 show the N.O. and N.C. contacts' connections. These
correspond to the jacks on the photoelectric sensor labeled N.O. and N.C.

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 When wiring the photoelectric sensor in this application, connect L1 to the
N.O. jack. Then, connect the jack labeled "C" (common) to the red lamp.
From the red lamp, connect to L2. Connect the red jack labeled "+" to
Ll. Connect the black jack labeled ":" to L2. This supplies power to the
photoelectric sensor.
o 3. Perform the sub steps to supply power to the trainer.
A. Place the 24 VDC power supply's power switch in the Off position.
B. Place the Electrical Control Module's power switch in the Off position.
C. Connect the #16019 24 VDC power supply to the Electrical Control
Module by plugging the power supply plug-in connector cable #16179
into the jack on the front of the trainer.
D. Turn on the main switch on the 24 VDC power supply.
o 4. Set up a test circuit using the photoelectric switch as shown in figure 42.
This circuit will turn on the red lamp whenever the photoelectric switch
senses an object. Notice that the power for the photoelectric switch is supplied
separately.

NOTE
The colors of the jacks are different than the wire colors.

POWER
SUPPLY
PHOTO
+24VDC
(+) ELECTRIC (-)
(RED)
RED SENSOR BLACK
JACKi---1 JACK
.----<~~PE~~_o--------.

ELECTRICAL CONTROL MODULE

2 •••• ----C:>-IC
""""""'"
SWITCHES

•'!,...

::c • :-t-:
•
•........-'-
:-..
..............,
3

BLACK
JACK(-)

PHOTOELECTRIC SWITCH

Figure 42. Photoelectric Switch Operation Setup Diagram

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 o 5. Turn on the control power switch.
o 6. Locate the LED on the front of the photoelectric sensor.
o 7. Pass your hand in front of the photoelectric sensor to see if you can make
the lamp go on. Then remove your hand to see if the lamp goes off. If this
happens, the system is working properly.
o 8. If continuing immediately to the next activity, skip to step 6 of that activity.
Otherwise, perform the substeps to shut down the trainer.
A. Turn off the control power switch of the Electrical Control Module.
B. Turn off the 24 VDC power supply.
C. Disconnect and store the electrical wires.
D. Return the photoelectric sensor to its storage location.

Activity 1. Sensing Range of a Photoelectric Sensor

Procedure Overview
In this activity, you will determine the sensing range of a photoelectric
sensor using several different objects.

o 1. Set up the Amatrol850 Electro-Fluid Power System Control Trainer.

o 2. Locate the photoelectric sensor shown.

Figure 43. 16096 Photoelectric Sensor

o 3. Ensure that the photoelectric sensor is attached to its bracket in the horizontal
position as shown.

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 o 4. Perform the substeps to supply power to the trainer.
A. Place the 24 VDC power supply's power switch in the Off position.
B. Place the Electrical Control Module's power switch in the Off position.
C. Connect the #16019 24 VDC power supply to the Electrical Control
Module by plugging the power supply plug-in connector cable #16179
into the jack on the front of the trainer.
D. Turn on the main switch on the 24 VDC power supply.
o 5. Set up the circuit shown.

POWER POWER
SUPPLY SUPPLY
PHOTO
+12VDC GND
(+) ELECTRIC (-)
(RED) (BLACK)
RED SENSOR BLACK
JACKj"- --I JACK
~---<~~PE~--~--------.

ELECTRICAL CONTROL MODULE

2 ••.• ----(>----11<

~
'!>...
0-----:--0
~
•
::c
-L

~
•
-L
0--:-0 3

RED
JACK (+)
©
'---'- ---'

PHOTOELECTRIC SWITCH

Figure 44. Photoelectric Switch Operation

o 6. Turn on the control power switch.

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 o 7. Test several types of objects to determine the range of sensing for each one.
Start with your hand as the object and place it in front of the sensor as shown
below so that the lamp is now on. Then slowly move it further away from
the sensor until the lamp turns off. Stop and measure this distance. This is
the range of the photoelectric sensor. Repeat this procedure several times to
verify your reading. Then record it in the chart below. Each time make sure
that the object is perpendicular to the beam.

PHOTOELECTRIC SWITCH
r- -

~f----~RANGE ~~

Figure 45. Determine Photoelectric Sensor Range

Hand
White Cardboard
Black Cardboard

o 8. Repeat step 7 using white cardboard and then black cardboard. Record the
range for each one of these objects in the chart above.

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 D 9. Now place a piece of white paper just inside the range distance so that the red
lamp is on. Then change the angle of the cardboard as shown below to see if
this has any effect on the detection by the sensor.

PHOTOELECTRIC SWITCH
r -

_ .J

Figure 46. Photoelectric Sensing Changing the Target Angle

Record below if this makes the lamp go off. Then move the cardboard slowly
closer to the photoelectric switch. Does the sensor eventually trip?

You should see that as you increase the amount ofthe angle, the photoelectric
sensor cannot detect the beam. This is because light that strikes a reflective
target is reflected away at the same angle that it strikes the object's surface. A
higher reflective surface should remain perpendicular to the sensor beam to
be detected.
If the object is rough or unpolished, the angle does not matter as much because
the beam is reflected off at many angles in approximately equal amounts.
As you move the angled target closer to the switch it will be detected at some
point, regardless of the angle.
D 10. Perform the sub steps to shutdown the trainer.
A. Turn off the control power switch of the Electrical Control Module
B. Turn off the 24 VDC power supply.
C. Disconnect and store the and electrical wires.
D. Return the Photoelectric Sensor to its storage location.

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 SEGMENT 3

1. Photoelectric sensors activate when they sense _

2. Photoelectric sensors are used in applications where an object needs to

be sensed without it.

3. An light source emits light in the infrared region.

4. A "modulated" light source means that the light source from the emitter
is pulsed at a certain _

5. An application requiring color differences to be detected would require

an type photoelectric sensor.

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 PHOTOELECTRIC SENSOR APPLICATIONS

OBJECTIVE 11

The way in which the photoelectric sensor's receiver receives the light beam
from its emitter is called the DETECTION METHOD or SCANNING TECH-
NIQUE. There are three primary detection methods used in industry:
• Direct
• Retro-reflective
• Proximity
Direct Detection
The direct detection method is shown in figure 48. It is called direct detection
because the receiver is positioned directly across from the emitter. This method,
also known as through-beam detection, is the most reliable way to detect the pres-
ence of an object because the light beam is not weakened by reflection off other
surfaces.
With direct detection, the object only has to block the beam and be opaque (not
allow light to pass through it) in order to deenergize the receiver and make it "see
dark". The object to be sensed can have any texture or color and in some cases be
translucent (light passes partially through it).
The disadvantage of this method is that it takes a sensor with two parts. This
increases cost and makes the installation more difficult.

EMITIER
I RECEIVER

\
LIGHT
BEAM

Figure 47. Direct Detection

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 Retro-Reflective Detection
The retro-reflective detection method uses reflective tape or a reflector similar
to a bicycle reflector. The emitter and receiver, as shown in figure 48, are located on
the same side and are usually contained in the same housing. The emitter is aimed
directly at the reflector, which reflects the light back to the receiver. If the object
breaks the beam, the receiver "sees dark" and the switch contacts deenergize. The
contacts reenergize when the object no longer breaks the beam.

OBJECT

,--------- --
lit
1
11
1
11
~

_
REFLECTOR
1
1 1
---------7------ OR TAPE

~---- -\-I
1 1 LIGHT BEAM

EMITTER AND RECEIVER

IN ONE PACKAGE

Figure 48. Retro-Reflective Detection

The retro-reflective detection method has the convenience of having both the
emitter and receiver built into one package. It also is excellent for use with translu-
cent materials, such as bottles, because the beam has to go through the bottle twice.
This degrades the signal which helps the photoelectric switch see dark when the
bottle is in front of it.

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 The disadvantage of retro-reflective scanning is that highly reflective objects
can reflect the light just like the reflector itself and make the receiver see light
when it should see dark. This problem occurs with both flat objects and cylindrical
objects passing perpendicular to the beam, as shown in figure 49. If the plane of
the flat reflective object is perpendicular to the beam, the beam reflects back to
the receiver and gives a false signal. To correct this problem, the sensor should be
aimed so that it strikes the object at an angle.
The problem of a falsely reflected signal is even worse for a cylindrical object
because the round surface reflects the signal back at any angle of rotation of the
cylinder. To solve this problem, the sensor should be aimed down at the object, as
shown in figure 49.

SEES DARK SEES LIGHT

(CORRECT ORIENTATION) (INCORRECT ORIENTATION)

•
SENSOR SENSOR
r----I
I I
I 1-----: REFLECTOR REFLECTOR
I I

I
L ..I

PATH
PATH

SENSOR , SENSOR
r----I ,
I I
I REFLECTOR REFLECTOR
I
L ..I

/
AIMED DOWN
PATH PATH

Figure 49. Correct and Incorrect Orientation of Objects with Retro-Reflective Section

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 Proximity Detection
Proximity detection works in a similar manner to retro-reflective detection
except the object itself is used to reflect the light beam. In this case, there is no
reflector so the sensor sees dark when an object is not present. When the object is
present, it reflects the light back to the photoelectric switch, causing the receiver
to see light.

SEES LIGHT
1- - - - - - - - - - - - - - - I LIGHT

i
1
:.1AM _ OBJECT

I 1

:- - - - - - - - - -/- - - -:
EMITTER AND
RECEIVER IN
ONE PACKAGE

Figure 50. Proximity Detection

When using proximity detection, the reflectivity of the object must be consid-
ered. The reflectivity is the amount of light reflected expressed as a percentage of
the total amount of light that strikes the object.

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 OBJECTIVE 12 EFIN ' LlGMl; CTIO

Objects detected by photoelectric sensors reflect the beam in one of two ways:
• Specular Reflection
• Diffuse Reflection
Specular Reflection
If the object is smooth and highly polished, it will reflect the beam off at the
same angle as it strikes the surface. This is called SPECULAR reflection and is
shown in figure 51.

,,
LIGHT BEAM

••
,, /
/

,, /

,, /
/
/

,, /
0, = O2
,, /
/
/

Figure 51. Specular Reflection

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 Diffuse Reflection
If the object is rough or unpolished, such as wood, the beam will be reflected
at all angles in approximately equal amounts. This is called DIFFUSE reflection
and is shown in figure 52.

Figure 52. Diffuse Reflection

As an example of how diffuse and specular reflection can be used with prox-
imity detection, consider the boxes on a conveyor shown in figure 53. When a
box is not present, the sensor sees dark because the beam is reflected off the shiny
surface of the conveyor. When a cardboard box is in place, diffuse reflection takes
place because the box is rough. This causes some light to be reflected back to the
sensor and it sees light. This type of sensor could be effectively used to signal a
labeling machine that a box is in position.

SEES LIGHT
SEES DARK

.•.. ~ .•.. ~
.•.. \
.•...•.. \
.•...•.. \ SENSOR ( \
\ \ \ \
\ \ \ \
\
\
\
V
.•..
\
.•...•..\

~
\
\ \
DIFFUSE
1
\
\
v--\
.•.. )

,
, ,
,
,
,
,
SPECULAR

I
I
.
I
I

•. \ \ I JI

n
, I
-'l-\!/:--"
1- D.\,/
····
BOX , I

II.
, ~j~~ _v~
\
CONVEYOR WITH
ALUMINUM SURFACE

Figure 53. Specular and Diffuse Reflection Characteristics

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 %

OBJECTIVE 13 DES IVE TEAl A EC

• Thi• The performance of a photoelectric sensor depends on several factors. Since an

• fIi
lit infrared sensor uses infrared light to detect objects, anything that affects infrared
light could affect the sensor's performance. Five characteristics that can have an
effect on photoelectric sensor performance are:
• Target Size
• Distance
• Sensor Beam Angle
• Target Material Reflectivity
• Target shape
Target Size
A larger target increases the sensing distance of a photoelectric sensor.

Distance
The closer a target is to a photoelectric sensor the more likely it is to be sensed.

PHOTOELECTRIC SWITCH

I~
r-------i RANGE

Figure 54. Photoelectric Sensor Range

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 Sensor Beam Angle
Light that strikes a highly polished target is reflected away at the same angle
that it strikes the object's surface (this is called specular reflection). The reflective
surface of highly polished objects, therefore, must remain perpendicular to the
sensor beam to be detected, as shown in figure 55.

LIGHT STRIKING OBJECT AT AN ANGLE

PHOTO-ELECTRIC
SENSOR

- - - - - - - - 1- - - - - -,'
~ 91,'
TRANSMITTER "",
92 .:
LIGHT IS \'
REFLECTED J;.' HIGHLY
POLISHED
AWAY FROM
RECEIVER OBJECT

OBJECT SURFACE PERPENDICULAR TO LIGHT BEAM

HIGHLY
TRANSMITTER POLISHED
7 OBJECT

===
<>==
==~~-~~
==:>

<:== G=
===0.

¢==
=0-

<l===
===c:> ====c>

<}= <:==

',,-- RECEIVER "'---- LIGHT IS

REFLECTED
BACK TO
RECEIVER

Figure 55. Specular Reflection

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 If the object is rough or unpolished, the angle does not matter as much because
the beam is reflected off at many angles in approximately equal amounts. This is
called diffuse reflection and is shown in figure 56.

TARGET WITH
ROUGH
SURFACE

TRANSMITTER 7 ///'>
//

/// ~ PORTION OF REFLECTED

LIGHT ENTERS RECEIVER

RECEIVER

PHOTO-ELECTRIC
SENSOR

Figure 56. Diffuse Reflection

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 Target Material Reflectivity
Reflectivity is the amount of light reflected by an object. This can be expressed
as a percentage of the total amount of light that strikes the object.
Different materials have different reflectivities as shown in figure 57. Mate-
rials, such as black pavement, reflect very little light while highly polished surfaces,
such as aluminum foil, reflect almost all of the light. The reflectivity is affected by
material type, color, and texture. A higher reflectivity is often desirable in prox-
imity detection because it will reflect the beam back to the sensor better.

Carbon Black
Black Pavement
Sandstone
Black Cloth
Felt (Black)
Zinc
Craft Paper (Brown)
White bond Paper
Aluminum Foil

Figure 57. Infrared Reflectivity of Typical Materials

It is important to note that the percentages given in the chart of figure 57 are
based on the use of infrared light. These percentages will differ if light visible to the
human eye is used. To understand how this can be used as an advantage, consider
the following example: black pavement and black felt cannot be distinguished by a
photoelectric switch that uses incandescent light. However, the infrared reflectivi-
ties are different by about 3:1 (23% vs. 8%). This is more than enough difference
for an infrared LED sensor to pick up.
Material type, color, and texture affect reflectivity. The reflectivity of several
materials is also shown in figure 57.
A higher degree of reflectivity is desirable when using reflective or diffuse
sensing because it will reflect the beam back to the sensor better.

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 Target Shape
The shape of a highly polished target can cause the transmitter beam to be
reflected away from the sensor's receiver, just as the sensor beam angle mentioned
earlier.
Flat and cylindrical objects passing perpendicular to the beam reflect the light
back to the sensor as shown in figure 58. If the plane of the flat reflective object
is perpendicular to the beam, the beam will reflect back to the receiver and give a
false signal. The round surface of a cylindrical object will reflect the signal back at
any angle of rotation of the cylinder.

SEES LIGHT
(INCORRECT ORIENTATION)

SENSOR

REFLECTOR

PATH

SENSOR

REFLECTOR

PATH

Figure 58. Photoelectric Retro-Reflection Off a Cylinder

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 SKILL 8 IRR
. ELECTRIC S

Procedure Overview
In this skill, you will design a circuit that uses a photoelectric sensor in
place of a limit switch to gage cylinder position. You will then connect and
operate your design.

o 1. Solve the following design problem.

Scenario: A company has a machine that needs to extend and retract a
cylinder, but because of the design of the machine, a limit switch cannot be
used to determine when the cylinder rod is fully extended. Use a photoelectric
sensor to determine when the cylinder is fully extended. Include the following
features in your circuit design.
• When the START pushbutton is momentarily pressed, the cylinder begins
to extend.
• The photoelectric sensor senses the cylinder rod at full extension.
• When the cylinder is fully extended, the cylinder retracts.
• A limit switch detects the position of the fully retracted cylinder.
• The cycle repeats continuously.
• Include an emergency STOP pushbutton that will retract the cylinder
immediately and stop it.

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 o 2. Draw your circuit on a separate piece of paper.

L1 L2

I
I
I
I
I
I
CYLINDER
~

1PE rrJl
•
~
11. ••••
I
I

!
_
I
I
o,. ....
1
I
:
J
1LS
..L!.
I
I
I
!
I
I
I

Figure 59. Setup for Cylinder Sequencing Circuit

o 3. Set up the Amatrol850 Electro-Fluid Power Systems Control trainer.

o 4. Perform the substeps to supply power to the trainer.
A. Place the 24 VDC power supply's power switch in the Off position.
B. Place the Electrical Control Module's power switch in the Off position.
C. Connect the #16019 24 VDC power supply to the Electrical Control
Module by plugging the power supply plug-in connector cable #16179
into the jack on the front of the trainer.
D. Turn on the main switch on the 24 VDC power supply.
o 5. Connect the control circuit that you designed in step 1.

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 o 6. Mount the photoelectric sensor on an angle as shown in figure 60.
This angle is required so that the sensor will sense the cylinder rod.

Figure 60. Photoelectric Sensor Mounted at Angle

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 D 7. Mount the photoelectric sensor on the slide track in the same manner as a
limit switch, as shown in figure 60. Position the photoelectric sensor so that
it is near the end of the cylinder's stroke.

Figure 61. Photoelectric Switch Mounting

D 8. Position the limit switch so that it is actuated when the cylinder becomes
fully retracted.
D 9. If using the hydraulic power unit, perform the following startup procedures.
If using the pneumatic trainer, skip to step 10.
A. Check the oil level. Fill if necessary.
B. Press the stop pushbutton on the motor starter to make sure the starter is
in the off position.
C. Plug in the power cord to the wall outlet.
D. Reduce the relief valve to its minimum pressure setting.
E. Close both flow control valves and then open each one turn.
F. Press the start button on the hydraulic power unit.
G. Adjust the relief valve pressure to 300 psi/2070 kPa.
H. Open the shutoff valve.
D 10. If using the pneumatic trainer, perform the following startup procedures. If
using the hydraulic trainer, skip to the next step.
A. Close both flow control valves and then open each one turn.
B. Connect the compressed air supply to the male quick-connect on the
instrumentation module.
C. Open the shutoff valve.
D. Adjust the regulator pressure to 30 psi/207 kPa.

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 011. Cycle the cylinder manually and observe the cylinder. It should extend at an
approximate rate of 2-3 seconds. If the cylinder speed needs adjusting, turn
the flow control valves until the desired speed is reached.
012. Turn on the control power switch.
013. Now manually extend the cylinder and hold it extended. Then position the
photoelectric switch so that it is actuated when the cylinder is fully extended.
You should be able to hear a "click" when the photoelectric switch actuates.
Also, a small red LED on the housing of the switch will come on.
014. Retract the cylinder and check the adjustment of the limit switch.
When the cylinder is retracted fully, the actuator arm of the limit switch
should be pressed down.
015. With both switches adjusted, press IPB momentarily to start the circuit.
You should observe that the cylinder now reciprocates continuously with the
photoelectric sensor sensing the extended position of the cylinder.
Record below your observations.

016. Press 2PB to stop the cycle.

017. Repeat steps 15 and 16 to become more familiar with the operation of the
photoelectric sensor.
018. Perform the substeps to shut down the electrical and hydraulic or pneumatic
power.
A. Turn off the control power switch of the Electrical Control Module.
B. Turn off the 24 VDC power supply.
C. If using the hydraulic trainer:
1. Reduce the power unit pressure to minimum.
2. Turn off the power unit.
3. Close the shutoff valve.
4. Manually activate each solenoid override to remove any pressure left in
the circuit. Trapped pressure can sometimes make it hard to disconnect
hoses.
D. If using the pneumatic trainer:
1. Reduce the regulator pressure to minimum.
2. Close the shutoff valve.
4. Manually activate each solenoid override to remove any pressure left in
the circuit.
E. Disconnect and store the hoses.
F. Disconnect and store the electrical wires.
G. Return the photoelectric sensor to its storage location.

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